Battery Conductive Module With Flexible Wiring for Terminal Misalignment
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Solution Overview
Problem
Conventional conductive modules suffer from reduced yield and increased size due to the use of flexible printed circuits with three-dimensional branch lines to accommodate terminal misalignment, necessitating additional space for tolerance absorption.
Innovation Solution
A conductive module design featuring a bus bar connected to electrode terminals, a rectangular flexible printed circuit, and flexible electric wires that absorb misalignment in multiple directions, eliminating the need for separate branch lines and reducing module size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible printed circuit with three-dimensional branch lines is used to accommodate terminal misalignment, then misalignment absorption is improved, but manufacturing yield deteriorates and device size increases
Solution Approach 1:
The invention changes the physical state of the connection from a rigid three-dimensional branch line structure to a flexible two-dimensional pattern that can be flattened. The branch lines are designed with flexible patterns including meander shapes and via holes that allow the circuit to absorb misalignment while maintaining a planar configuration, thereby improving manufacturing yield without sacrificing adaptability
Solution Approach 2:
The invention creates a simplified two-dimensional copy of the connection path that replicates the electrical connection function without requiring the complex three-dimensional spatial arrangement. By copying the connection function in a flattened configuration with flexible patterns, the design achieves both manufacturing efficiency and misalignment absorption
2Adaptability or versatility
If a flexible printed circuit with three-dimensional branch lines is used to accommodate terminal misalignment, then misalignment absorption is improved, but device size increases
Solution Approach 1:
The invention transitions the branch line configuration from three-dimensional spatial arrangement to a two-dimensional planar pattern. The flexible patterns including meander shapes and via holes enable misalignment absorption within the plane of the circuit board, eliminating the need for additional three-dimensional space while maintaining the misalignment absorption function
Solution Approach 2:
The invention nests the misalignment absorption function within the existing two-dimensional circuit board area by incorporating flexible patterns and via holes into the planar structure. The meander shapes and via holes are embedded within the circuit trace paths, allowing the circuit to accommodate misalignment without requiring separate space for tolerance absorption
3Adaptability or versatility
If a flexible printed circuit with three-dimensional branch lines is used, then misalignment absorption is improved, but device complexity increases
Solution Approach 1:
The invention simplifies the circuit structure by changing the configuration from three-dimensional branch lines to two-dimensional flexible patterns. The flexible patterns including meander shapes and via holes provide misalignment absorption capability while maintaining a simpler planar structure that is easier to manufacture and assemble compared to complex three-dimensional arrangements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves improved yield and suppresses size increase by utilizing flexible electric wires to absorb terminal misalignment, ensuring accurate assembly and efficient manufacturing.
Implementation Method 1
an electric wire for each of the bus bars that has flexibility and electrically connects the bus bar to the flexible printed circuit
Data Source
AI summary
A conductive module includes a bus bar that is physically and electrically connected to an electrode terminal of a battery cell, a flexible printed circuit that is molded in a rectangular shape extending in an arrangement direction of the plurality of battery cells, and electrically connects between a battery monitoring unit and the bus bar, and an electric wire for each of the bus bars that has flexibility and electrically connects the bus bar to the flexible printed circuit. The flexible printed circuit includes a circuit conductor for each of the bus bars that electrically connects the bus bar to the battery monitoring unit, and a pad portion for each of the bus bars that is provided adjacent to the bus bar and is electrically connected to the circuit conductor for the bus bar.